Textile product and production method thereof

ABSTRACT

The present invention provides a textile product and a method of manufacturing thereof, the textile product being applicable also to a target product having a complicated shape because an electric/electronic function is given to the textile product. The present invention is a textile product manufactured by using a knitted or woven fabric, wherein the knitted or woven fabric comprises a knitted or woven filamentous electronic-function member in at least part of the knitted or woven fabric, wherein the electronic-function member comprises a core portion comprising at least two metal wires, an insulating layer that covers the at least two metal wires so as to expose part of the at least two metal wires, and an electronic-function portion electrically conducted to each of the at least two metal wires and a sheath portion comprising a knitted fabric that covers the core portion, and wherein a yarn containing thermoplastic resin is included in at least part of the knitted fabric of the electronic-function member, and/or the yarn containing thermoplastic resin is interwoven with the electronic-function member.

CROSS REFERENCE TO RELATED APPLICATIONS

This is the U.S. national stage of application No. PCT/JP2017/045571,filed on Dec. 19, 2017. Priority under 35 U.S.C. § 119(a) and 35 U.S.C.§ 365(b) is claimed from Japanese Patent Application No. 2017-104834,filed May 26, 2017; the disclosures of which are incorporated herein byreference.

TECHNICAL FIELD

The present invention relates to a textile product and a method ofmanufacturing thereof, and specifically relates to a textile producthaving an electric/electronic function and a method of manufacturingthereof.

BACKGROUND ART

Conventionally, various sensors such as a vibration sensor, atemperature sensor, and a pressure sensor have been attached toindustrial equipment for the purpose of detecting abnormality of theindustrial equipment. In order to achieve the above purpose, forexample, a packaged rectangular sensor (for example, PatentLiterature 1) is used for industrial equipment serving as a measurementtarget (hereinafter, referred to as “target product”).

However, the packaged rectangular sensor can be disposed in a case wherethe target product has a flat portion, but, in a case where the targetproduct has a complicated shape such as a curved surface, the sensorcannot be easily attached to the target product. Thus, it is problematicin that measurement is difficult.

CITATION LIST

Patent Literature 1: JP 2008-03087 A

SUMMARY OF INVENTION Technical Problem

In a case where the sensor can also be attached to a target producthaving a complicated shape, it is possible to easily measure vibration,temperature, pressure, and the like, regardless of a shape of the targetproduct. It is also possible to give an electric/electronic functionincluding not only a sensor function but also a control function such astemperature control and a communication function.

The inventors of the present invention have focused on a stretchabletextile product and have intended to provide a textile product and amethod of manufacturing thereof, the textile product being applicablealso to a target product having a complicated shape because anelectric/electronic function is given to the textile product.

Solution to Problem

In order to achieve the above-mentioned object, a textile productaccording to a first aspect of the present invention is a textileproduct manufactured by using a knitted or woven fabric, in which: theknitted or woven fabric comprises a knitted or woven filamentouselectronic-function member in at least part of the knitted or wovenfabric; the electronic-function member comprises a core portionincluding at least two metal wires, an insulating layer that covers theat least two metal wires so as to expose part of the at least two metalwires, and an electronic-function portion electrically conducted to eachof the at least two metal wires and a sheath portion including a knittedfabric that covers the core portion; and a yarn containing thermoplasticresin is included in at least part of the knitted fabric of theelectronic-function member, and/or the yarn containing thermoplasticresin is interwoven with the electronic-function member.

According to the above-mentioned first aspect, the thermoplastic resinexisting in the vicinity of the electronic-function member can be meltedand solidified by heating a region including the electronic-functionmember. With this configuration, it is possible to form the regionincluding the electronic-function member in accordance with a shape ofthe target product. This makes it possible to easily attach theelectronic-function member also to a target product having a complicatedshape.

Further, a textile product according to a second aspect of the presentinvention is a textile product manufactured by using a knitted or wovenfabric, in which: the knitted or woven fabric comprises a knitted orwoven filamentous electronic-function member in at least part of theknitted or woven fabric;

the electronic-function member includes a core portion including atleast two metal wires, an insulating layer that covers the at least twometal wires so as to expose part of the at least two metal wires, and anelectronic-function portion electrically conducted to each of the atleast two metal wires and a sheath portion including a knitted fabricthat covers the core portion; and at least part of the knitted fabric ofthe electronic-function member and/or at least part around theelectronic-function member contains solidified thermoplastic resin.

According to the above-mentioned second aspect, it is possible to formthe region including the electronic-function member in accordance withthe shape of the target product. This makes it possible to easily attachthe electronic-function member also to a target product having acomplicated shape.

Further, in the textile product according to a third aspect of thepresent invention, the core portion is sealed from outside in a regionin which the core portion is covered by the knitted fabric.

According to the above-mentioned third aspect, it is possible to improvewater resistance of the sheath portion of the electronic-functionmember.

Further, in the textile product according to a fourth aspect of thepresent invention, the sheath portion includes a first covering portionthat is made from the knitted fabric and is provided on a side of thecore portion and a second covering portion that covers at least part ofthe first covering portion and presses the first covering portion to thecore portion.

According to the above-mentioned fourth aspect, it is possible tofurther bring the first covering portion of the electronic-functionmember into tight contact with the core portion.

Further, in the textile product according to a fifth aspect of thepresent invention, the second covering portion is a long memberhelically wound around the first covering portion.

According to the above-mentioned fifth aspect, in theelectronic-function member, it is possible to bring the first coveringportion into tight contact with the core portion, without damaging thecore portion.

Further, in the textile product according to a sixth aspect of thepresent invention, the electronic-function portion is selected from thegroup consisting of a chip component, an electronic-function-substancecontaining film, a battery, an input element, a display element, asensor, an antenna, a composite element thereof, and an integratedcircuit thereof.

According to the above-mentioned sixth aspect, it is possible to furtherreduce size and thickness of the electronic-function member to bemounted. This makes it possible to further thin the electronic-functionmember.

Further, in the textile product according to a seventh aspect of thepresent invention, the core portion includes a plurality of theelectronic-function portions, and the plurality of electronic-functionportions form a circuit by being connected to each other with the atleast two metal wires.

According to the above-mentioned seventh aspect, it is possible tofurther reduce the size of the electronic-function member by using acircuit, instead of a component such as a chip.

Further, in the textile product according to an eighth aspect of thepresent invention, the circuit includes sensor portions as theelectronic-function portions.

According to the above-mentioned eighth aspect, it is possible to usethe electronic-function member as measuring tools.

Further, in the textile product according to a ninth aspect of thepresent invention, the circuit further includes, as theelectronic-function portions, a control portion that controls operationof the sensor portions, a communication portion that outputs informationfrom the sensor portions to outside, and a power supply portion thatsupplies power to the sensor portions, the control portion, and thecommunication portion.

According to the above-mentioned ninth aspect, it is possible to furtherreduce the size of the electronic-function member serving as measuringtools.

Further, an invention according to a tenth aspect of the presentinvention provides a method of manufacturing the textile productaccording to the first aspect, the method comprising a step ofmanufacturing a knitted or woven fabric at least part of which isinterwoven with an electronic-function member, the step comprisinginterweaving the electronic-function member including the yarncontaining thermoplastic resin in at least part of the knitted fabricand/or interweaving the electronic-function member and the yarncontaining thermoplastic resin in at least part of a region of theknitted or woven fabric.

According to the above-mentioned tenth aspect, it is possible to providea textile product having an electric/electronic function, the textileproduct being a product in which a region including theelectronic-function member is formable in accordance with the shape ofthe target product.

Further, an invention according to an eleventh aspect of the presentinvention provides a method of manufacturing the textile productaccording to the second aspect, the method comprising: a step ofmanufacturing a knitted or woven fabric at least part of which isinterwoven with the electronic-function member, the step includinginterweaving the electronic-function member including the yarncontaining thermoplastic resin in at least part of the knitted fabricand/or interweaving the electronic-function member and the thermoplasticresin filament in at least part of a region of the knitted or wovenfabric; and a step of melting and solidifying the yarn containingthermoplastic resin interwoven into the knitted or woven fabric.

According to the above-mentioned eleventh aspect, by melting andsolidifying the thermoplastic resin existing inside or in the vicinityof the electronic-function member, it is possible to form the regionincluding the electronic-function member in accordance with the shape ofthe target product. This makes it possible to provide a textile producthaving an electric/electronic function and being applicable also to atarget product having a complicated shape.

Advantageous Effect of Invention

According to the present invention, it is possible to provide a textileproduct having an electric/electronic function and being applicable alsoto a target product having a complicated shape.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a partial cutaway plan view showing an example of a structureof an electronic-function member for use in a textile product accordingto Embodiment 1 of the present invention.

FIG. 2 is a schematic vertical-sectional view of the electronic-functionmember shown in FIG. 1.

FIG. 3 is a developed diagram showing an example of a structure ofknitted fabric for use in the electronic-function member shown in FIG.1.

FIG. 4A is a schematic plan view showing an example of a structure ofknitted goods for use in the textile product according to Embodiment 1of the present invention.

FIG. 4B is a schematic vertical-sectional view of theelectronic-function member shown in FIG. 4A.

FIG. 5A is a schematic plan view showing another example of thestructure of the knitted goods for use in the textile product accordingto Embodiment 1 of the present invention.

FIG. 5B is a schematic vertical-sectional view of an electronic-functionmember shown in FIG. 5A.

FIG. 6A is a schematic plan view showing another example of thestructure of the knitted goods for use in the textile product accordingto Embodiment 1 of the present invention.

FIG. 6B is a schematic vertical-sectional view of an electronic-functionmember shown in FIG. 6A.

FIG. 7 is a partial cutaway plan view showing an example of a structureof an electronic-function member for use in a textile product accordingto Embodiment 3 of the present invention.

FIG. 8 is a schematic vertical-sectional view of the electronic-functionmember shown in FIG. 7.

FIG. 9 is a partial cutaway plan view showing an example of a structureof an electronic-function member for use in a textile product accordingto Embodiment 4 of the present invention.

FIG. 10 is a schematic vertical-sectional view of theelectronic-function member shown in FIG. 9.

FIG. 11 is a partial cutaway plan view showing an example of a structureof an electronic-function member for use in a textile product accordingto Embodiment 5 of the present invention.

FIG. 12 is a schematic vertical-sectional view of theelectronic-function member shown in FIG. 11.

FIG. 13 is a schematic diagram showing an example of a structure of anelectronic-function member for use in a textile product of the presentinvention.

FIG. 14 is a block diagram showing an example of an internal circuit ofthe electronic-function member for use in the textile product accordingto Embodiment 5 of the present invention.

DESCRIPTION OF EMBODIMENT

Hereinafter, embodiments of the present invention will be described indetail with reference to the drawings as appropriate.

Embodiment 1

A textile product according to this embodiment is a textile productmanufactured by using a knitted or woven fabric, in which: the knittedor woven fabric comprises a knitted or woven filamentouselectronic-function member in at least part of the knitted or wovenfabric; the electronic-function member comprises a core portionincluding at least two metal wires, an insulating layer that covers theat least two metal wires so as to expose part of the at least two metalwires, and an electronic-function portion electrically conducted to eachof the at least two metal wires, and a sheath portion including aknitted fabric that covers the core portion; and a yarn containingthermoplastic resin is included in at least part of the knitted fabricof the electronic-function member, and/or the yarn containingthermoplastic resin is interwoven with the electronic-function member.

The present invention provides the textile product manufactured by usinga knitted or woven fabric that is obtained by weaving or knitting yarnsof natural fibers, semisynthetic fibers, or synthetic fibers. A shape,dimensions, thickness, and the like thereof are not particularlylimited.

(Electronic-Function Member)

FIG. 1 is a partial cutaway plan view of an electronic-function memberfor use in this embodiment. FIG. 2 is a vertical-sectional view takenalong line II-II′ of FIG. 1. An electronic-function member 1 includes acore portion 5 and a sheath portion 20 covering the core portion 5. Thecore portion 5 includes a first insulation-covered metal wire 10 and asecond insulation-covered metal wire 11 extending in a longitudinaldirection thereof and an electronic-function portion 12 electricallyconducted to each of the first and second insulation-covered metal wires10 and 11. Knitted fabric 21 is used as the sheath portion 20. Further,a chip component is used as the electronic-function portion 12.

As shown in FIG. 2, the first insulation-covered metal wire 10 includesa metal wire 10 a covered by an insulating layer 10 b, and the secondinsulation-covered metal wire 11 includes a metal wire 11 a covered byan insulating layer 11 b. Part of the insulating layer 10 b is removed,and a joining portion 16 is formed to be in contact with the exposedmetal wire 10 a. Further, part of the insulating layer 11 b is removed,and a joining portion 17 is formed to be in contact with the exposedmetal wire 11 a. The electronic-function portion 12 has a rectangularshape and includes a pair of external electrodes 12 a and 12 b servingas electronic-function portions at both end portions. By connecting theexternal electrode 12 a to the joining portion 16 and connecting theexternal electrode 12 b to the joining portion 17, theelectronic-function portion 12 is electrically connected to the metalwire 10 a and the metal wire 11 a. The electronic-function portion 12and the metal wires 10 a and 11 a, which are electrically connected toeach other as described above, are covered by the knitted fabric 21.Note that the joining portions 16 and 17 may be formed as a structuredifferent from joining material by plating or the like. However, in acase where the insulating layers 10 b and 11 b are thin, joiningmaterial such as solder or a conductive adhesive can form the joiningportions 16 and 17. Further, in a region in which the core portion 5 iscovered by the knitted fabric 21, the core portion 5 is sealed from theoutside.

Copper wires and nickel wires can be used as the metal wires forming thecore portion. Copper wires are preferable. A diameter of each metal wireis not particularly limited, as long as the metal wire can be formedinto knitted fabric. However, the diameter is 1 μm or more and 1 mm orless, and is preferably 1 μm or more and 0.5 mm or less. Further, theinsulating layer prevents the metal wires from being brought into directcontact with each other, and polyurethane resin, acrylic resin, or along insulating sheet or tape can be used. In this embodiment, theinsulating layer exposes part of each metal wire in order to secureelectrical conduction with the electronic-function portion. Herein, thepart of the metal wire merely means “not the whole surface of the metalwire”, and an area of the part is not particularly limited.

Further, the electronic-function portion has a function of an activeelement such as a transistor, a diode, or a Peltier element and afunction of a passive element such as a resistor, a capacitor, aninductor, or a thermistor and can be selected from the group consistingof a chip component, an electronic-function-substance containing film, abattery, an input element, a display element, a sensor, an antenna, acomposite element thereof, and an integrated circuit thereof.

The passive element may be a chip component or may be anelectronic-function-substance containing film, such as a thick filmresistor, a thin film resistor, a thin film capacitor, or a thin filminductor. Further, the passive element may be organic material,composite material, or paste material containing an electronic-functionsubstance. The electronic-function-substance containing film can beformed by applying a solution containing element material, for example,dielectric material to surfaces of the plurality of metal wires by usinga publicly-known thick-film printing method such as spin coating orscreen printing and performing heat processing. Further, it is alsopossible to use an electronic-function-substance containing filmpatterned by a thin film process. In that case, for example, it ispossible to use a lift-off method, vapor deposition, spattering, or thelike. In the lift-off method, after a resist is applied to the surfacesof the plurality of metal wires, the resist is patterned by lithography,then a solution containing element material is applied, and the resistis removed thereafter. This makes it possible to leave an intended thinfilm pattern. Specific examples of the electronic-function portionencompass an NTC thermistor, a PTC thermistor, and a Peltier element. Ina case where those elements are used for clothing including theelectronic-function member, for example, the NTC thermistor is used, itis possible to measure temperature of the clothing. Further, in a casewhere the PTC thermistor is used, it is possible to warm the clothing.Furthermore, in a case where the Peltier element is used, it is possibleto cool the clothing.

Further, the electronic-function portion includes a plurality ofterminal portions that exchange signals with an external device.Specific examples of the terminal portions encompass an externalelectrode, a terminal, and an electrode pad. For example, in a casewhere two terminal portions are two terminals, one terminal can beconnected to one metal wire, and the other terminal can be connected tothe other metal wire.

The sheath portion includes knitted fabric covering the core portion andcan be formed as one or more covering portions laminated on a peripheryof the core portion. Although knitted fabric can be used as any coveringportion, it is preferable to use knitted fabric as a first coveringportion that is provided on a side of the core portion and at least partof which is in contact with the core portion. In this embodiment, therewill be described an example where the sheath portion includes only thefirst covering portion made from knitted fabric.

FIG. 3 shows a developed diagram of the knitted fabric 21. The knittedfabric 21 can be formed as tubular knitted fabric covering a peripheryof the core portion 5 by weft knitting using a knitting yarn. Weftknitting is preferable because stitches thereof are finer than those ofwarp knitting. Further, in weft knitting, stitches are formed bywrapping the knitting yarn around the vertical core portion, and thusthe core portion can be fastened comparatively strongly by the knittingyarn of the sheath portion. This makes it possible to bring the sheathportion into tight contact with the core portion.

In this embodiment, a yarn containing thermoplastic resin is included inat least part of the knitted fabric of the electronic-function member,and/or a yarn containing thermoplastic resin is woven with theelectronic-function member. By heating a region including theelectronic-function member, it is possible to melt and solidify thethermoplastic resin existing in the vicinity of the electronic-functionmember. With this configuration, it is possible to form the regionincluding the electronic-function member in accordance with a shape ofthe target product. This makes it possible to easily attach theelectronic-function member also to a target product having a complicatedshape.

In a case of an electronic-function member in which the yarn containingthermoplastic resin (hereinafter, also referred to as “thermoplasticfilament yarn”) is included in the at least part of the knitted fabricof the electronic-function member, for example, the knitted fabric canbe manufactured by using the thermoplastic filament yarn as a knittingyarn of at least part of the knitted fabric. Examples of thermoplasticresin encompass polyurethane resin, polyethylene resin, polyester resin,polyamide resin, and polypropylene resin. It is preferable to use athermoplastic synthetic filament yarn made from thermoplastic resin suchas polyethylene resin, polyester resin, polyamide resin, andpolypropylene resin. Further, the thickness of the knitting yarn ispreferably 33 dtex or more and 250 dtex or less. In a case where thethickness is less than 33 dtex, the core portion is not sufficientlycovered by the knitted fabric. Meanwhile, in a case where the thicknessis more than 250 dtex, it is difficult to knit the knitted fabric byusing a knitting machine because the knitting yarn is too thick. It isalso possible to use a plurality of thermoplastic filament yarns madefrom thermoplastic resins having different melting points or a compositefilament yarn including a thermoplastic filament yarn, anon-thermoplastic yarn, and other yarns.

Also in a case where the thermoplastic filament yarn is woven with theelectronic-function member, it is possible to weave or knit the knittedfabric by using the similar thermoplastic filament yarn.

Further, the number of stitches in a single course of the knitted fabricis not particularly limited, but is preferably two or more and eight orless. A diameter of the tubular knitted fabric can be reduced, and thusit is possible to further improve the tight contact of the knittedfabric to the core portion.

Further, the number of stitches per natural length of 1 cm in a singlewale of the knitted fabric is not particularly limited, but ispreferably six or more and fourteen or less. Herein, the term “naturallength” means length of the knitted fabric to which no tension or thelike is given, i.e., length of the knitted fabric that is naturallyplaced on a table as it is. In a case where the number of stitches pernatural length of 1 cm in a single wale of the knitted fabric is six ormore, it is possible to improve coverage of the core portion with theknitted fabric. Further, in a case where the number of stitches pernatural length of 1 cm in a single wale of the knitted fabric isfourteen or less, it is possible to restrain a defect from occurring,the defect being caused by a tuck defect of stitches of the knittedfabric because the stitches are too fine.

In a case where the thermoplastic filament yarn is used as a knittingyarn of the knitted fabric, the thermoplastic filament yarn existing inthe vicinity of the electronic-function member is melted and solidifiedas described above. This makes it possible not only to form a regionincluding the electronic-function member in accordance with the shape ofthe target product but also to obtain the following effects.Specifically, heating and melting the thermoplastic filament yarnincluded in the knitted fabric improves the coverage of the core portionwith the cooled and solidified knitted fabric and the tight contact ofthe cooled and solidified knitted fabric to the core portion. This makesit possible to protect the electronic-function member and the metalwires from moisture at the time of washing or sweating. Further, byheating the thermoplastic filament yarn while applying pressure thereto,it is possible to further improve the tight contact between the coreportion and the sheath portion. In a case where a composite filamentincluding a plurality of thermoplastic filament yarns having differentmelting points is used as a knitting yarn, the composite filament isheated at temperature that is higher than a melting point of athermoplastic filament yarn having a low melting point but is lower thana melting point of a thermoplastic filament yarn having a high meltingpoint. Thus, the thermoplastic filament yarn having the high meltingpoint maintains a state of the knitted fabric, and only thethermoplastic filament yarn having the low melting point is melted. Thismakes it possible to improve durability.

Further, the electronic-function member can be manufactured by using,for example, the following method. Specifically, the method includes: astep of forming a core portion including at least two metal wires, aninsulating layer that covers the at least two metal wires so as toexpose part of the at least two metal wires, and an electronic-functionportion electrically conducted to each of the at least two metal wires;and a step of forming a sheath portion that covers the core portion, inwhich the step of forming the sheath portion includes at least a step ofknitting knitted fabric around the core portion by weft knitting andcovering the core portion.

The step of forming the core portion can further include: a step offorming a conductive pattern on a plurality of metal wires; and a stepof mounting at least one electronic-function portion on the plurality ofmetal wires. In a case where, for example, two metal wires are used, asshown in FIG. 2, part of the insulating layer on a surface of each metalwire is removed to expose a surface of the metal wire, and a joiningportion to which a conductive pattern is given is formed. The number ofconductive patterns can be selected in accordance with the number ofinput/output terminals of the electronic-function portion or the numberof electronic-function portions. Further, the conductive pattern canhave various shapes such as a line, a rectangle, a circle, and a dot. Ina case where the electronic-function portion is mounted on a pluralityof metal wires, it is preferable, in view of stretchiness anddurability, that the electronic-function portion be mounted on theplurality of metal wires parallel to each other in a directionperpendicular to a longitudinal direction of the plurality of metalwires. Further, in a case where a plurality of electronic-functionportions are mounted in the longitudinal direction of the metal wires,it is possible to form a plurality of conductive patterns atpredetermined intervals in the longitudinal direction of the metalwires. The conductive patterns can be formed by a printing method usinga conductive paste or an electroplating method.

In the step of covering the core portion, tubular knitted fabriccovering the periphery of the core portion can be formed by weftknitting using a knitting yarn by using a circular knitting machine. Thecircular knitting machine can be a publicly-known circular knittingmachine as disclosed in, for example, JP S60-193993 U.

(Method of Manufacturing a Knitted or Woven Fabric)

A knitted or woven fabric for use in this embodiment can be manufacturedby supplying the electronic-function member to a weaving machine andmanufacturing a woven fabric or supplying the electronic-function memberto a knitting machine and manufacturing knitted goods. Specifically, amethod of manufacturing a knitted or woven fabric for use in thisembodiment comprises a step of manufacturing a knitted or woven fabricat least part of which is interwoven with the electronic-functionmember, and the step comprises interweaving the electronic-functionmember including the yarn containing thermoplastic resin in at leastpart of the knitted fabric and/or interweaving the electronic-functionmember and the yarn containing thermoplastic resin in at least part of aregion of the knitted or woven fabric.

Hereinafter, a case of a knitted fabric will be described. Anelectronic-function member including a yarn containing thermoplasticresin (thermoplastic filament yarn) as a knitting yarn of knitted fabricis supplied alone to a knitting machine (knitting method 1).Alternatively, an electronic-function member including no thermoplasticfilament yarn as a knitting yarn of knitted fabric and one or morenatural filament yarns, semisynthetic filament yarns, synthetic filamentyarns, or the like including at least a thermoplastic filament yarn arecombined and are supplied to a knitting machine (knitting method 2).Alternatively, an electronic-function member including a thermoplasticfilament yarn as a knitting yarn of knitted fabric and one or morenatural filament yarns, semisynthetic filament yarns, and syntheticfilament yarns including at least a thermoplastic filament yarn arecombined and are supplied to a knitting machine (knitting method 3). Amethod of combining the electronic-function member and a normalsynthetic filament yarn is, for example, supplying theelectronic-function member and the normal synthetic filament yarn fromdifferent yarn paths of face yarns and forming knitted fabric orsupplying the electronic-function member and the normal syntheticfilament yarn from the same yarn path of a face yarn, arranging theelectronic-function member and the normal synthetic filament yarn inparallel, and forming knitted fabric. The knitted fabric can be formedby flat knitting, rib knitting, interlock knitting, pearl knitting, pileknitting, or the like. Further, the electronic-function member and thenormal synthetic filament yarn can be supplied from a yarn guide of aface yarn and a yarn path of a back yarn, respectively, and can besubjected to plating knitting. Further, in view of an economical point,the electronic-function member can be interwoven only into a specificnecessary part by intarsia knitting (interlock knitting).

The knitting method 1 is a method of supplying the electronic-functionmember including a thermoplastic filament yarn as a knitting yarn ofknitted fabric alone to a knitting machine. However, a plating yarnand/or a back yarn can also be used as necessary. In that case, anatural filament yarn, a semisynthetic filament yarn, or a syntheticfilament yarn including no thermoplastic filament yarn can be used asthe plating yarn and the back yarn. With this configuration, at the timeof heat processing, it is possible to prevent a melted thermoplasticfilament yarn from falling.

Next, the knitting method 2 will be described. In the knitting method 2,a plating yarn and/or a back yarn are/is used. FIG. 4A is a schematicplan view showing an example of a structure of knitted goods, and FIG.4B is a schematic vertical-sectional view of the knitted goods. Knittedgoods 70A is knitted by using an electronic-function member 71, a backyarn 72, and a plating yarn 73. The kind of yarn for use in knittedfabric forming a sheath portion of the electronic-function member 71 isnot particularly limited and can be, for example, a natural filamentyarn, a semisynthetic filament yarn, or a synthetic filament yarnincluding no thermoplastic filament yarn. Further, a natural filamentyarn, a semisynthetic filament yarn, or a synthetic filament yarnincluding at least a thermoplastic filament yarn is used as the platingyarn and the back yarn. In a case where one of the plating yarn and theback yarn includes a thermoplastic filament yarn, the other yarn can beomitted, or a non-melted filament yarn, for example, a regeneratedfilament yarn such as rayon or a thermoplastic filament yarn that is notmelted at temperature at which the one of the yarns is melted can beused as described below. Further, both the plating yarn and the backyarn may include a thermoplastic filament yarn.

In FIG. 4A and FIG. 4B, a thermoplastic filament yarn is used as theplating yarn 73. The back yarn 72 has a function of, at the time of heatprocessing of the knitted goods, preventing the melted plating yarn 73from falling and holding the melted plating yarn 73. The plating yarn 73is melted and solidified by the heat processing, and thus rigidity isincreased. By performing the heat processing with respect to a regionincluding the electronic-function member in the knitted goods inaccordance with a predetermined mold so that the region matches with theshape of the target product, it is possible to melt and solidify theregion and form the region in a predetermined shape.

FIG. 4A and FIG. 4B show an example where the plating yarn 73 isinterwoven into the whole surface of the knitted goods 70A. However, theplating yarn 73 may be interwoven only in a predetermined region.Further, FIG. 4A and FIG. 4B show an example where a thermoplasticfilament yarn is used only as the plating yarn 73. However, athermoplastic filament yarn melted at a melting point of the platingyarn 73 or less may also be used as the back yarn 72. It is possible toform a plane resin region covering a periphery of theelectronic-function member.

FIG. 5A is a schematic plan view showing another example of thestructure of the knitted goods, and FIG. 5B is a schematicvertical-sectional view of the knitted goods. Knitted goods 70B isknitted, by moss stitch, by using a face yarn 74, the back yarn 72, andthe plating yarn 73 including a thermoplastic filament yarn. Anelectronic-function member is used as the face yarn 74. By knitting theknitted goods 70B by seed stitch, it is possible to interweave theplating yarn 73 in a pattern. For example, in the knitted goods 70B, aregion in which the electronic-function portion is to be disposed isformed by interweaving the plating yarn 73 and the back yarn 72, and theother parts are formed by interweaving the face yarn 74 and the backyarn 72. Further, the face yarn 74 and the plating yarn 73 seem to becut at an end portion 74 a and an end portion 73 a. However, in anactual knit structure, the face yarn and the plating yarn are providedcrosswise by a technique of floating the face yarn and the plating yarnon a reverse side of the knitted fabric, which is also referred to as“float stitch”. In other words, a part in which the face yarn 74 iswoven and the plating yarn 73 is caused to pass on the reverse side anda part in which the plating yarn 73 is woven and the face yarn 74 iscaused to pass on the reverse side are disposed in a moss-stitch shape.

Further, as shown in FIG. 5B, in a case where the knitted goods 70B isformed by moss stitch, the plating yarn 73 is formed in a mesh shape,and the knitted fabric and the plating yarn are subjected to heatprocessing, it is possible to further restrain the region including theelectronic-function portion from being easily folded or broken. Further,by using the transparent plating yarn 73 containing no matting materialand not using the back yarn 72 or using a transparent thermoplasticfilament yarn containing no matting material also as the back yarn 72,it is possible to cause the region including the electronic-functionportion to be transparent.

FIG. 6A is a schematic plan view showing another example of thestructure of the knitted goods, and FIG. 6B is a schematicvertical-sectional view of the woven fabric. Knitted goods 70C isknitted, by cut-boss stitch, by using the face yarn 74, the back yarn72, and the plating yarn 73 including a thermoplastic filament yarn. Anelectronic-function member is used as the face yarn 74. By knitting theknitted goods 70C by cut-boss stitch, it is possible to interweave theplating yarn 73 in a pattern. For example, in the knitted goods 70C, aregion in which the electronic-function portion is to be disposed isformed by interweaving the plating yarn 73 and the back yarn 72, and theother parts are formed by interweaving the face yarn 74 and the backyarn 72. Further, the face yarn 74 and the plating yarn 73 are cut in apart 75 where the face yarn 74 and the plating yarn 73 overlap. This isdifferent from the case of moss stitch shown in FIG. 5A.

Next, the knitting method 3 will be described. In the knitting method 3,an electronic-function member including a thermoplastic filament yarn asa knitting yarn of knitted fabric, a plating yarn, and/or a back yarnare used. A natural filament yarn, a semisynthetic filament yarn, or asynthetic filament yarn including at least a thermoplastic filament yarnis used as the plating yarn and the back yarn. In a case where one ofthe plating yarn and the back yarn includes a thermoplastic filamentyarn, the other yarn can be omitted, or a non-melted filament yarn, forexample, a regenerated filament yarn such as rayon or a thermoplasticfilament yarn that is not melted at temperature at which the one of theyarns is melted can be used as described below. Further, both theplating yarn and the back yarn may include a thermoplastic filamentyarn.

Further, the knitted or woven fabric can include at least one powersupply portion that is electrically connected to the electronic-functionportion. The electronic-function portion and the power supply portioncan be electrically connected by the metal wires forming the coreportion. Thus, it is unnecessary to additionally provide a lead wire andconnect the electronic-function portion and the power supply portion.With this configuration, it is possible to easily connect theelectronic-function portion and the power supply portion. An externaldevice that can be electrically connected to the electronic-functionportion is not limited to the power supply portion and can be a signalgenerator, a transmitting device, a receiving device, a detectingdevice, a measuring device, a display device, an input device, or thelike.

According to this embodiment, it is possible to provide a textileproduct having an electric/electronic function and being applicable alsoto a target product having a complicated shape. Further, in theelectronic-function member to which the electric/electronic function isgiven, an external device such as a power supply portion and theelectronic-function portion can be electrically connected by the metalwires forming the core portion. This makes it possible to easily connectthe external device and the electronic-function portion.

Embodiment 2

A textile product according to this embodiment is a textile productobtained by melting and solidifying thermoplastic resin contained in thetextile product according to Embodiment 1. The textile product accordingto this embodiment is different from the textile product according toEmbodiment 1 in that at least part of knitted fabric of anelectronic-function member and/or at least part around theelectronic-function member contains solidified thermoplastic resin.

In the textile product according to this embodiment, at least part ofthe knitted fabric of the electronic-function member and/or at leastpart around the electronic-function member contains solidifiedthermoplastic resin, and, by melting and solidifying thermoplasticresin, it is possible to form a region including the electronic-functionmember in accordance with the shape of the target product. Further, byfusing the solidified thermoplastic resin to another knitting yarn, itis possible to integrate the electronic-function member with a knittedor woven fabric. With this configuration, even in a case where theknitted or woven fabric is expanded or contracted, theelectronic-function member does not crack or peel off the knitted orwoven fabric. Further, it is possible to improve rigidity of a region inwhich the electronic-function portion is disposed, increase strengththereof, and reduce elongation thereof. This makes it possible torestrain the region from being deformed and improve durability of theelectronic-function portion.

Hereinafter, a method of manufacturing thereof will be described. Amethod of manufacturing the textile product according to thisembodiment, the method includes: a step of manufacturing a knitted orwoven fabric at least part of which is interwoven with theelectronic-function member, the step including interweaving theelectronic-function member including the yarn containing thermoplasticresin in at least part of the knitted fabric and/or interweaving theelectronic-function member and the yarn containing thermoplastic resinin at least part of a region of the knitted or woven fabric; and a stepof melting and solidifying the yarn containing thermoplastic resininterwoven into the knitted or woven fabric.

In this method, in a case where the electronic-function member isinterwoven with the yarn containing thermoplastic resin (thermoplasticfilament yarn), the thermoplastic filament yarn may be a thermoplasticfilament yarn having a melting point lower than that of another knittingyarn or a thermoplastic filament yarn having a melting point equivalentto that of another knitting yarn. In a case where the thermoplasticfilament yarn having the melting point lower than that of anotherknitting yarn is used, it is preferable to use a thermoplastic filamentyarn having a melting point that is lower by 30° C. or more than amelting point of another knitting yarn and is more preferably lower by50° C. or more than the melting point.

Note that heating temperature for melting and solidifying thethermoplastic filament yarn can be appropriately set in accordance witha melting point of a thermoplastic filament yarn to be used. However, itis necessary that the heating temperature do not exceed an upper limitof heat resistant temperature of the electronic-function portionincluded in the electronic-function member.

Regarding a combination of knitting yarns, in the example of FIG. 4A,the knitted goods is knitted by using a natural filament yarn or asynthetic filament yarn having a comparatively high melting point (asynthetic filament yarn having a melting point higher than that of thethermoplastic filament yarn) as the sheath portion of theelectronic-function member and using a fiber having a comparatively highmelting point (a filament yarn having a melting point higher than thatof the thermoplastic filament yarn) such as nylon or polyurethane as theback yarn. After knitting, by heating only the region in which theelectronic-function portion is disposed or the whole surface of theknitted goods while applying pressure to the region or the whole surfaceas necessary, only the thermoplastic filament yarn having the lowestmelting point is melted and solidified.

Table 1 shows exemplary combinations of thermoplastic filament yarns tobe melted and serving as a knitting/weaving yarn for use in a knitted orwoven fabric and other knitting/weaving yarns. Herein, non-melted fibersin Table 1 are fibers other than thermoplastic fibers to be melted andindicate fibers for use in the sheath portion of the electronic-functionmember or the back yarn, and melted fibers indicate thermoplastic fibersto be melted.

TABLE 1 Non-melted fibers Melted fibers Difference in melting pointPolyester fiber (Melting Nylon 6 fiber Approximately 50 degrees point:260° C.) Polyvinyl chloride fiber Approximately 50 degrees Vinylon fiberApproximately 30 degrees Polypropylene fiber Approximately 100 degreesPolyethylene fiber Approximately 130 degrees Low-melting polyester fiberApproximately 150 degrees Low-melting nylon fiber Approximately 150degrees Polyurethane fiber Polypropylene fiber Approximately 50 degrees(Melting point: 230° C.) Polyethylene fiber Approximately 80 degreesLow-melting polyester fiber Approximately 100 degrees Nylon 6 fiber(Melting Polypropylene fiber Approximately 50 degrees point: 215° C.)Polyethylene fiber Approximately 80 degrees Low-melting polyester fiberApproximately 100 degrees Low-melting nylon fiber Approximately 100degrees Cotton (Decomposition Polypropylene fiber Approximately 70degrees point: 235° C.) Low-density polyethylene fiber Approximately 100degrees Hemp (Decomposed at Polypropylene fiber Approximately 40 degrees200° C.) Polyethylene fiber Approximately 70 degrees Rayon(Decomposition Nylon 6 fiber Approximately 50 degrees is started at 260°C. Polyvinyl chloride fiber Approximately 50 degrees or more) Vinylonfiber Approximately 30 degrees Polypropylene fiber Approximately 100degrees Low-density polyethylene fiber Approximately 130 degreesLow-melting polyester fiber Approximately 150 degrees Low-melting nylonfiber Approximately 150 degrees p-aramid resin Polyester fiberApproximately 140 degrees (Carbonized at 400° C. Nylon 6 fiberApproximately 190 degrees or more) Polyvinyl chloride fiberApproximately 190 degrees Vinylon fiber Approximately 170 degrees

Combinations of the melted fibers and the non-melted fibers are notlimited to the range shown in Table 1, and melting points of thenon-melted fibers only need to be higher by 30° C. or more than meltingpoints of the melted fibers.

Embodiment 3

A textile product in this embodiment has a configuration similar to thatof a textile product in Embodiment 1, except that the sheath portionincluding a first covering portion that is made from knitted fabric andis in contact with the core portion and a second covering portion thatcovers at least part of the first covering portion and presses the firstcovering portion to the core portion is used as the electronic-functionmember.

FIG. 7 is a partial cutaway plan view of the electronic-function memberaccording to this embodiment, and FIG. 8 is a vertical-sectional viewtaken along line VIII-VIII′ in FIG. 7. Hereinafter, a part common toEmbodiment 1 will not be described, and only a different part will bedescribed.

An electronic-function member 2 includes a core portion 5 and a sheathportion 20 covering the core portion 5. The sheath portion 20 furtherincludes a first covering portion 22 made from knitted fabric andexisting on a side of the core portion 5 and a second covering portion23 wound around the first covering portion 22. The second coveringportion 23 presses the first covering portion 22 to the core portion 5,thereby further bringing the first covering portion 22 into tightcontact with the core portion 5.

The second covering portion can be a long member. The long member can beas follows: a natural filament yarn made from cotton, hemp, wool, or thelike; a semisynthetic filament yarn made from cellulose or the like; asynthetic filament yarn made from nylon, acryl, polyester, polyurethane,or the like; or a composite yarn, a tape, a string, or the like obtainedby combining a plurality of fiber materials. By using the long member,it is possible to bring the first covering portion into tight contactwith the core portion, without damaging the core portion. Further, in acase where a synthetic filament yarn containing thermoplastic resin isused as the first covering portion, a synthetic filament yarn containingthermoplastic resin can also be used as the second covering portion. Bycovering the first covering portion with the second covering portion andthereafter heating and melting the synthetic filament yarn, it ispossible to further improve the tight contact of the first coveringportion to the core portion after cooling.

Further, the following examples can also be used as a combination of thefirst covering portion and the second covering portion. For example, ina case where a synthetic filament yarn containing thermoplastic resin isused as the first covering portion, it is possible to use a yarn madefrom the above-mentioned non-melted fiber (hereinafter, referred to as“non-melted filament yarn”) as the second covering portion. Further, itis possible to use a non-melted filament yarn as the first coveringportion and use a synthetic filament yarn containing thermoplastic resinas the second covering portion. Also in those cases, it is possible toimprove the tight contact of the first covering portion to the coreportion.

The electronic-function member for use in this embodiment can bemanufactured by using a method including a step of helically winding thelong member around the first covering portion after the first coveringportion is formed. By using a publicly-known sheath yarn windingapparatus disclosed in, for example, JP S63-282304 A, the secondcovering portion can be formed by drawing a string wound around a bobbinwhile rotating the bobbin and winding the string around theelectronic-function member while moving, in an upward direction ordownward direction, the electronic-function member on which the firstcovering portion has been formed. Note that winding intervals of thesecond covering portion in a longitudinal direction of theelectronic-function member can be adjusted as necessary. By reducing thewinding intervals (or increasing the number of times of winding), it ispossible to further improve the tight contact of the first coveringportion to the core portion. Further, it is also possible to furtherimprove the tight contact of the first covering portion to the coreportion by increasing a diameter of the yarn forming the second coveringportion to reduce the winding intervals.

According to this embodiment, in addition to the effect of Embodiment 1,the following effects can be obtained by providing the second coveringportion: it is possible to further improve the tight contact of thefirst covering portion to the core portion and further improvedurability of the electronic-function member.

Note that, although this embodiment shows an example where the secondcovering portion is provided, it is also possible to provide anothercovering portion as necessary. For example, the second covering portionis helically wound in the longitudinal direction of theelectronic-function member, and, in addition, a third covering portioncan be wound around the second covering portion in an opposite directionof a direction of the second covering portion so as to cross the secondcovering portion. By providing the third covering portion, it ispossible to further improve the tight contact of the first coveringportion to the core portion.

Further, a paralleled yarn including a synthetic filament yarncontaining thermoplastic resin may be provided between the core portionand the first covering portion. Also in this case, it is also possibleto improve the tight contact of the first covering portion to the coreportion. In this case, combinations of the first covering portion andthe second covering portion can be as follows: a case where syntheticfilament yarns containing thermoplastic resin are used as both the firstcovering portion and the second covering portion; a case wherenon-melted filament yarns are used as both the first covering portionand the second covering portion; and a case where a synthetic filamentyarn containing thermoplastic resin is used as one of the first coveringportion and the second covering portion and a non-melted filament yarnis used as the other.

Embodiment 4

A textile product according to this embodiment has a configurationsimilar to that of the textile product in Embodiment 1, except that anelectronic-function member including an electronic-function-substancecontaining film is used as the electronic-function portion, instead of achip component.

FIG. 9 is a partial cutaway plan view of an electronic-function memberaccording to this embodiment, and FIG. 10 is a vertical-sectional viewtaken along line X-X′ of FIG. 9. Hereinafter, a part common toEmbodiment 1 will not be described, and only a different part will bedescribed.

An electronic-function member 3 includes a core portion 6 and a sheathportion 20 covering the core portion 6. The core portion 6 includes afirst insulation-covered metal wire 10, a second insulation-coveredmetal wire 11, and an electronic-function portion 13 including anelectronic-function-substance containing film and provided to beelectrically conducted to each of the first and secondinsulation-covered metal wires 10 and 11.

As described above, the electronic-function-substance containing filmcan be formed by applying a solution containing element material, forexample, dielectric material to surfaces of a plurality of metal wiresby using a publicly-known printing method such as spin coating andperforming heat processing. Further, it is also possible to use apatterned thin film. Herein, the electronic-function substanceencompasses dielectric material, conductive material, magnetic material,piezoelectric material, semiconductor material, pyroelectric material,and the like.

According to this embodiment, in addition to the effect of Embodiment 1,the following effects can be obtained by using theelectronic-function-substance containing film: size and thickness of theelectronic-function portion to be mounted on the metal wires can beflexibly changed, and thus it is possible to provide a textile productthat can be optimally designed in accordance with use of theelectronic-function member.

Embodiment 5

A textile product according to this embodiment has a configurationsimilar to that of the textile product in Embodiment 1, except that along insulating member is used as the insulating layer covering themetal wires and an electronic-function member including anelectronic-function-substance containing film formed to cover aperiphery of the plurality of metal wires in a strip shape is used asthe electronic-function portion, instead of a chip component.

FIG. 11 is a partial cutaway plan view of an electronic-function memberaccording to this embodiment, and FIG. 12 is a vertical-sectional viewtaken along line XII-XII′ of FIG. 11. An electronic-function member 4includes a core portion 7 and a sheath portion 20 covering the coreportion 7. The core portion 7 includes: metal wires 10 a and 11 aextending in a longitudinal direction and between which an insulatingmember 15 is interposed; and an electronic-function-substance containingfilm 14 formed to cover a periphery of the metal wires 10 a and 11 a ina strip shape and provided to be electrically conductible to the metalwires 10 a and 11 a. Knitted fabric 21 is used as the sheath portion 20.

An insulating member of the electronic-function member for use in thisembodiment can be a long insulating sheet interposed between the metalwires, an insulating tape attached in the longitudinal direction of themetal wires, an insulating layer formed in the longitudinal direction ofthe metal wires, or the like. The insulating layer can be made frompolyurethane resin, acrylic resin, or the like.

As described above, the electronic-function-substance containing filmcan be formed by applying a solution containing element material, forexample, dielectric material to surfaces of a plurality of metal wiresby using a publicly-known printing method such as spin coating andperforming heat processing. Further, it is also possible to use apatterned thin film element.

According to this embodiment, in addition to the effect of Embodiment 1,the following effects can be obtained by using theelectronic-function-substance containing film: size and thickness of theelectronic-function portion to be mounted on the metal wires can beflexibly changed, and thus it is possible to provide a textile productthat can be optimally designed in accordance with use of theelectronic-function member.

Examples of a single electronic-function portion have been described inEmbodiments 1 to 5. However, the electronic-function member for use inthe textile product of the present invention can also include aplurality of electronic-function portions. For example, theelectronic-function member may include: a first electronic-functionportion provided to be electrically conductible to each of at least twometal wires included in the first wiring portion; and a secondelectronic-function portion different from the first wiring portion andprovided to be electrically conductible to each of at least two metalwires included in a second wiring portion. Similarly, theelectronic-function member may further include a third wiring portionand a third electronic-function portion, a fourth wiring portion and afourth electronic-function portion, a fifth wiring portion and a fifthelectronic-function portion, and the like. The first electronic-functionportion may be different from the other electronic-function portions, orall electronic-function portions may be the same. For example, atemperature sensor element (for example, NTC thermistor) is used as thefirst electronic-function portion, and a heater element (for example,PTC thermistor) is used as the second electronic-function portion.

FIG. 13 is a schematic diagram showing an example of a structure of theabove-mentioned electronic-function member including the plurality ofelectronic-function portions, and the sheath portion is not shown. Acore portion 30 includes metal wires 31, 32, 33, 34, 35, and 36, each ofwhich is covered by an insulating layer. The two metal wires 31 and 32form a first wiring portion 37, the two metal wires 33 and 34 form asecond wiring portion 38, and the two metal wires 35 and 36 form a thirdwiring portion 39. A first electronic-function portion 41 is joined to ajoining portion 31 a obtained by exposing part of the metal wire 31 anda joining portion 32 a obtained by exposing part of the metal wire 32.Further, a second electronic-function portion 42 is joined to a joiningportion 33 a obtained by exposing part of the metal wire 33 and ajoining portion 34 a obtained by exposing part of the metal wire 34.Further, a third electronic-function portion 43 is joined to a joiningportion 35 a obtained by exposing part of the metal wire 35 and ajoining portion 36 a obtained by exposing part of the metal wire 36.Although FIG. 13 shows an example where six metal wires are disposed inparallel, the six metal wires can also be bundled while preventing thefirst to third electronic-function portions from being brought intocontact with each other.

Further, the electronic-function member for use in the textile productof the present invention may form a circuit by connecting a plurality ofelectronic-function portions to each other with at least two metalwires. This form will be described in more detail in the followingEmbodiment 6.

Embodiment 6

In an electronic-function member for use in a textile product accordingto this embodiment, a core portion includes a plurality ofelectronic-function portions, and the plurality of electronic-functionportions forms a circuit by being connected to each other with at leasttwo metal wires (hereinafter, the circuit will also be referred to as“internal circuit”). FIG. 14 is a block diagram showing an example of aconfiguration of the internal circuit. A circuit 60 includes a pluralityof circuit element portions forming the circuit, and the circuit elementportions correspond to the electronic-function portions. The circuit 60includes, as the circuit element portions, a passive element portion 61,an active element portion 62, a control portion 63 that controlsoperation of the passive element portion 61 and the active elementportion 62, a communication portion 64 that exchanges a communicationsignal with the outside, a power supply portion 65 that supplies powerto each portion, an A/D converter portion 66 that A/D-converts a datasignal received from the passive element portion 61 and outputs theconverted data signal to the control portion 63, a D/A converter portion67 that D/A-converts a control signal received from the control portion63 and supplies the converted control signal to the active elementportion 62, a transmitting/receiving antenna portion 68 that performswireless transmission/reception with respect to the outside, and awireless charging portion 69 that receives an electric wave for powerfrom the outside and outputs power generated from the electric wave forpower to the power supply portion 65. Further, the circuit 60 includes,as an external device, a display portion 70 that displays predeterminedimage information received from the control portion 63.

The passive element portion 61 can be, for example, a sensor as apassive element. In that case, the passive element portion will also bereferred to as “sensor portion”. The sensor can be a temperature sensor,an infrared sensor, a humidity sensor, a sound sensor, an opticalsensor, a magnetic sensor, a pressure sensor, an acceleration sensor, aposition sensor, or the like. Further, the active element portion 62 canbe, for example, a heater element or an oscillating element as an activeelement. A combination of the passive element and the active element canbe variously selected in accordance with use of the electronic-functionmember. For example, it is possible to give a temperature adjustingfunction to the electronic-function member by using a temperature sensoras the passive element and a heater element as the active element.Further, the power supply portion 65 can be, for example, a capacitor ora secondary battery.

The plurality of electronic-function portions can be connected to eachother by, for example, disposing the plurality of electronic-functionportions in a longitudinal direction of the two metal wires andelectrically conducting the electronic-function portions to therespective metal wires.

The electronic-function member for use in this embodiment can also beformed as knitted goods by using a method similar to the methoddescribed in Embodiment 1. That is, it is possible to manufactureknitted goods by supplying the electronic-function member including theinternal circuit to a knitting machine and using the electronic-functionmember as a normal yarn.

According to this embodiment, in addition to the effect of Embodiment 1,the following effect can be obtained by using a circuit, instead of aplurality of components such as chips: it is possible to provide atextile product including a smaller electronic-function member.

Note that, in this embodiment, circuit element portions other than thepassive element portion and the active element portion can also beprovided as external devices, instead of being included in theelectronic-function member. In that case, although the external devicesare held by the knitted goods, the circuit element portions other thanthe passive element portion and the active element portion and theexternal devices can be electrically connected with the metal wiresforming the core portion, as described in Embodiment 1.

Further, the circuit element portions shown in FIG. 14 are merely anexample, and it is possible to use various circuit element portions inaccordance with use.

Hereinabove, embodiments of the present invention have been described.However, a person skilled in the art can understand that thoseembodiments are merely examples and various modification examples can bemade within the scope of the present invention. For example, Embodiment3 shows an example where a knitting yarn is helically wound around thefirst covering portion as the second covering portion. However, thesecond covering portion may be formed by using knitted fabric or may beformed by employing plating knitting.

INDUSTRIAL APPLICABILITY

According to the present invention, it is possible to provide a textileproduct having an electric/electronic function and being applicable alsoto a target product having a complicated shape.

REFERENCE SIGNS LIST

-   -   1, 2, 3, 4 electronic-function member    -   5, 6, 7 core portion    -   10 first insulation-covered metal wire    -   11 second insulation-covered metal wire    -   10 a, 11 a metal wire    -   10 b, 11 b insulating layer    -   12, 13, 14 electronic-function portion    -   12 a, 12 b external electrode    -   15 insulating member    -   16, 17 joining portion    -   20 sheath portion    -   21 knitted fabric    -   22 first covering portion    -   23 second covering portion    -   30 core portion    -   31, 32, 33 metal wire    -   34, 35, 36 metal wire    -   31 a, 32 a, 33 a joining portion    -   34 a, 35 a, 36 a joining portion    -   37 first wiring portion    -   38 second wiring portion    -   39 third wiring portion    -   41 first electronic-function portion    -   42 second electronic-function portion    -   43 third electronic-function portion    -   60 circuit    -   61 passive element portion    -   62 active element portion    -   63 control portion    -   64 communication portion    -   65 power supply portion    -   66 A/D converter portion    -   67 D/A converter portion    -   68 transmitting/receiving antenna portion    -   69 wireless charging portion    -   70A, 70B, 70C knitted goods    -   71 electronic-function member    -   72 back yarn    -   73 plating yarn    -   73 a end portion of plating yarn    -   74 face yarn    -   74 a end portion of face yarn    -   75 part in which face yarn and thermoplastic fiber overlap

1. A textile product manufactured by using a knitted or woven fabric,wherein the knitted or woven fabric comprises a knitted or wovenfilamentous electronic-function member in at least part of the knittedor woven fabric, wherein the electronic-function member comprises a coreportion comprising at least two metal wires, an insulating layer thatcovers the at least two metal wires so as to expose part of the at leasttwo metal wires, and an electronic-function portion electricallyconducted to each of the at least two metal wires and a sheath portioncomprising a knitted fabric that covers the core portion, and wherein ayarn containing thermoplastic resin is included in at least part of theknitted fabric of the electronic-function member, and/or the yarncontaining thermoplastic resin is interwoven with theelectronic-function member.
 2. A textile product manufactured by using aknitted or woven fabric, wherein, the knitted or woven fabric comprisesa knitted or woven filamentous electronic-function member in at leastpart of the knitted or woven fabric, wherein the electronic-functionmember comprises a core portion including at least two metal wires, aninsulating layer that covers the at least two metal wires so as toexpose part of the at least two metal wires, and an electronic-functionportion electrically conducted to each of the at least two metal wiresand a sheath portion including a knitted fabric that covers the coreportion, and wherein at least part of the knitted fabric of theelectronic-function member and/or at least part around theelectronic-function member contains solidified thermoplastic resin. 3.The textile product according to claim 1, wherein the core portion issealed from outside in a region where the core portion is covered by theknitted fabric.
 4. The textile product according to claim 1, wherein thesheath portion comprises a first covering portion that is made from theknitted fabric and is provided on a side of the core portion and asecond covering portion that covers at least part of the first coveringportion and presses the first covering portion to the core portion. 5.The textile product according to claim 4, wherein the second coveringportion is a long member helically wound around the first coveringportion.
 6. The textile product according to claim 1, wherein theelectronic-function portion is selected from the group consisting of achip component, an electronic-function-substance containing film, abattery, an input element, a display element, a sensor, an antenna, acomposite element thereof, and an integrated circuit thereof.
 7. Thetextile product according to claim 1, wherein the core portion comprisesa plurality of the electronic-function portions, and wherein theplurality of electronic-function portions form a circuit by beingconnected to each other with the at least two metal wires.
 8. Thetextile product according to claim 7, wherein the circuit comprisessensor portions as the electronic-function portions.
 9. The textileproduct according to claim 8, wherein the circuit further comprises, asthe electronic-function portions, a control portion that controlsoperation of the sensor portions, a communication portion that outputsinformation from the sensor portions to outside, and a power supplyportion that supplies power to the sensor portions, the control portion,and the communication portion.
 10. A method of manufacturing the textileproduct according to claim 1, the method comprising: a step ofmanufacturing a knitted or woven fabric at least part of which isinterwoven with the electronic-function member, wherein the stepcomprises interweaving the electronic-function member including the yarncontaining thermoplastic resin into at least part of the knitted fabricand/or interweaving the electronic-function member and the yarncontaining thermoplastic resin in at least part of a region of theknitted or woven fabric.
 11. A method of manufacturing the textileproduct according to claim 2, the method comprising: a step ofmanufacturing a knitted or woven fabric at least part of which isinterwoven with the electronic-function member, the step comprisinginterweaving the electronic-function member including the yarncontaining thermoplastic resin in at least part of the knitted fabricand/or interweaving the electronic-function member and the yarncontaining thermoplastic resin in at least part of a region of theknitted or woven fabric; and a step of melting and solidifying the yarncontaining thermoplastic resin interwoven into the knitted or wovenfabric.
 12. The textile product according to claim 2, wherein the coreportion is sealed from outside in a region where the core portion iscovered by the knitted fabric.
 13. The textile product according toclaim 2, wherein the sheath portion comprises a first covering portionthat is made from the knitted fabric and is provided on a side of thecore portion and a second covering portion that covers at least part ofthe first covering portion and presses the first covering portion to thecore portion.
 14. The textile product according to claim 13, wherein thesecond covering portion is a long member helically wound around thefirst covering portion.
 15. The textile product according to claim 2,wherein the electronic-function portion is selected from the groupconsisting of a chip component, an electronic-function-substancecontaining film, a battery, an input element, a display element, asensor, an antenna, a composite element thereof, and an integratedcircuit thereof.
 16. The textile product according to claim 2, whereinthe core portion comprises a plurality of the electronic-functionportions, and wherein the plurality of electronic-function portions forma circuit by being connected to each other with the at least two metalwires.
 17. The textile product according to claim 16, wherein thecircuit comprises sensor portions as the electronic-function portions.18. The textile product according to claim 17, wherein the circuitfurther comprises, as the electronic-function portions, a controlportion that controls operation of the sensor portions, a communicationportion that outputs information from the sensor portions to outside,and a power supply portion that supplies power to the sensor portions,the control portion, and the communication portion.